Switch



M. w. MORRIS SWITCH March 21, 1939.

Filed May 1o. 1955 3 sheets-sheet 1 March 21, 1939. MQ w. MORRIS SWITCH Filed May 10, 1955 3 Sheets-Sheet 2 March 21, 1939. M. w. MORRIS 2,151,512

SWITCH I Filed May 10, 1935 5 Sheets-Sheet 5 92 Insulation fig/0. 97

E I I f Inf/@non 137.! Mafia/2 JM-Mff l 5A l `59 v K A w y @www Patented Mar. 21, 1939 UNITED STATES SWITCH Marion W. Morris, Logansport, Ind., assignor to R-B-M Manufacturing Company, Logansport, Ind., a corporation of Indiana Application May 10,

Claims.

This invention relates to switches, and more particularly is directed to a dimming switch construction for automobiles or the like, in which the headlights of the vehicle are controlled byl operation of the switch, the switch preferably being actuated by reciprocatory movement produced by the drivers foot. However, the principles underlying the construction and operation of the switch structure disclosed are equally applicable Ato switch structures employed for other purposes,

such as wall switches, room lights, motor control switches and the like.

In switches of the type now in use for dimming purposes upon vehicles and the like with which I am familiar, the operation has been secured by rotation of a contact assembly about a xed axis, whereby a Contact carrying ring or the like is successively rotated by step-by-step movement about the surfaces of xed Contact terminals, so n that the alternating engagement of the contact ring with the terminals connected to the circuit controls the operation of the lights. Rotation of theassembly has been secured by depression of a plunger member under the control of the drivers foot, there being a ratchet mechanism or similar motion transmission means, such as a rack and pinion or the like, providing for the successive rotation of the contact assembly upon successive depressions of the plunger. Such switch structures are subjected to rapid wear, and consequent faulty operation, since jamming of the ratchet mechanism is likely to occur, with consequentv slippage of the plunger therepast, producing no actuation of the switch. v

Further, the cost of manufacture and assembly of such switches is considerable, due to the necessity of precisionin forming the ratchet mechanism, the machined shaft about which the mechalism rotates, and the supporting bearings there- One of the primary objects of the present invention is the provision of a relatively cheap and economical switch structure of the plunger-operated type, which may be readily assembled, and the parts of which are almost entirely formed from sheet metal stampings, requiring no machining or nishing operations.

Another object of the present invention is the provision of a switch of this type having rela- 50 tively few parts, which are simple in design, and which operate in a positive and enicient manner.

Switches of this general type-are subjected to unusually hard and rough usage, due to the fact that they are foot-operated, and are also subjected to considerable vibration, being mounted 1935, serial No. 20,821 (ol. 20o-67) on the floorboard of the vehicle adjacent the clutch member or in a similar convenient position. The present invention is adapted to provide a switch of rugged and sturdy design, which is snap-actuated from one position to the other, and which is locked in each of its operating positions to prevent displacement or disruption of the contact engagement caused by vibration of the switch assembly or the like. This, together with the wiping action of the contact member across the contact terminals, provides a positive acting and eicient switch mechanism of simplilied design.

An additional advantage secured by the present invention is the separation, by means of suitable insulation, of the electrical circuit and contact terminals from any portion of the switch operating mechanism.

A further feature of the present invention is the provision of a contact switching member which maybe spring pressed into engagement 20 with the contact terminals, or the provision of contact terminals which are resiliently urged toward the switch bridging member, whereby` a positive wiping action between the contacts and bridging member is secured during actuation of the switch, thus maintaining the contact surfaces clean and bright.

Another advantage secured by the present invention is the provision of a spring-controlled A cam lever having a lost motion knuckle or toggle connection with the actuating plunger and carried thereby, the lever snapping the contact switching member positively from one of its operating positions to the other.

The switch disclosed in the presentvinvention 35- also possesses another distinctly advantageous characteristic in that the construction is so designed that the contact bridging member can never be maintained in intermediate position between the switch contacts, but is snap-actuated from one contact to the other, with a rapid snap movement that prevents stalling of the bridging member intermediate the contacts. This is of distinct advantage in preventing the occurrence of blind spots during the interval in which the switching operation is taking place, since in certain switches of the prior art I have found that it is necessary to provide for continuous and complete downward movement of the plunger in order to swing the switch mechanism from one positionl to its other position, and if the downward movement of the plunger is not completed, the switch may stall in an intermediate position and thus provide no headlight 55 illumination whatsoever until the motion of the plunger has been completed. In the present switch, when the plunger once passes its toggle position, the switch leaves the first contact engaging position and moves to a contact engaging position with a snap action, whereby no further movement of the plunger is necessary after the switch initially begins to move off of its first contact engaging position.

OtheiI objects and advantages of the present invention will appear more fully from the following detailed description, which taken in conjunction with the accompanying drawings, will disclose to those skilled in the art the particular f construction and operation of a preferred form ol the present invention.

In the drawings:

Figure l is a front elevational view of the switch mechanism of the present invention;

Figure 2 is a corresponding View, in section, showing the interior construction of the switch mechanism and the plunger housing;

Figure 2A is a sectional View taken on line 2A-2A of Figure 2;

Figure 3 is a view corresponding to Figure 2, in which the switch is shown as it is snapping from one of its circuit closing positions to a second circuit closing position;

Figure 3A is a sectional view corresponding to Figure 2 and illustrating the switch in its operative circuit closing position;

Figure 4 is a front elevational View of a modified form of switch;

Figure 5 is a front sectional view of the switch shown in Figure 4;

Figure 5A is a sectional view taken substantially on line 5A5A of Figure 5;

Figure 6 is a view showing the continuation of the operation initiated by downward movement of the plunger in the mechanism shown in Figure 5;

Figure 7 is a detail perspective View of one of the switch parts;

Figure 8 is a corresponding View of the other of the switching elements;

Figure 9 is a perspective view of the spring member for snapping the switch from one to another of its switching positions; and

Figure 10j is a perspective view of the bridging member-and insulating support therefor ern ployed with the switch shown in Figures 4 to 6.

Referring now to the structure shown in Figures 1 to 3, inclusive, I provide a switch mounting plate or bracket 5, which is provided with the extruded openings 6 adapted to receive suitable securing means for mounting the plate 5 upon a oor-board or upon any other suitable supporting means.

Secured to the plate 5, either by welding, riveting or the like, is a rectangular switch housing I having a back wall portion, flanged edges terminating at one end in outwardly extending shoulders 8 which are secured to the bracket 5 for supporting the housing in position, and an upturned end 9 having normally extending anges II) which are welded or otherwise suitably secured to the side edges of the housing 1.

Upon the opposite side of the plate 5 is provided a cylindrical metal tube I2, which may be provided with integral tab portions or the like extending through the plate into the interior housing 'l and riveted or peened over to secure the cylinder I2 in position. The cylinder I2 is adapted to receive the plunger I3 which is riveted to the cap member I4 as shown in Figure 2, the

plunger I3 having a bifurcated lower end I5 into which extends an insulating barrier member I6, the barrier member I6 being secured within the lower end of the plunger by means oi the pin Il.

The lower end o the barrier member I6 is provided with a reduced portion I8, adapted to receive a leaf spring member I9 which bears against the upper camming surfaces of a pair of operating links 2D pivoted on the pin 22 carried at the lower end of the barrier I5. The spring I9 normally urges the links 2U toward each other as shown in Figure 2.

A helically coiled spring member 23 is biased at its upper end against the inner surface of the cap I4, and at its lower end bears upon the top of the bracket 5, extending about the upper end of the insulating member I6, the spring encircling the plunger and normally urging the plunger upwardly into the position shown in Figure 2.

The open face of the housing 1 is closed by an insulating terminal plate 25, which plate 25 is adapted to carry a pair of external contact terminals 2B and 2l leading to the bright and dim circuits of the headlights, and also carries a supply terminal 28 leading to the battery or other source of current supply. The terminal plate 25 is secured upon the open i'ace of the housing by means or a plurality of tabs 29 formed integral with the housing and bent over suitably notched portions of the terminal plate when the terminal plate is disposed over the face of the housing.

The terminals 26 and 2l are secured in position by means of rivets 30 which extend through the terminal plate and on the inner side of the terminal plate are adapted to secure a pair of resilient contact spring members 32 and 33 in position, the contacts 32 and 33 being preferably formed of spring bronze, copper or the like, and having bent over planar surfaces adapted to be engaged by a contact bridging member for completing a circuit between the input supply terminal 28 and the headlight circuit.

The supply terminal 28 is secured to the plate 25 by means of a rivet 34, which, together with a rivet member 35, is adapted to secure a supporting bracket 35 in position upon the inner lace of the terminal plate 25. The bracket 36 has a normally extending offset portion 37 provided with a tongue portion 38 extending parallel to the plane oi the terminal plate 25 and spaced inwardly therefrom toward the base oi' the housing l. A suitable leaf spring member 39 is disposed in the U-shaped channel formed by the bracket 36 and the parallelly extending spaced tongue 38, bearing at its under surface on the normally extending base 31 of the Ue shaped channel, and having an offset tongue portion carried within a suitable slot 40 formed in tht tongue 38.

A pair ol cooperating elongated slots 42 are formed in the upper end of the tongue 38 and a raised portion offset from the plane ol the bracket 36. The slots form guides for a pin member 43 extending therethrough and having recip-v rocatory movement in the slots.

Within the channel yformed by the bracket 35 and the extending tongue 33 are disposed a pair of toggle links 44 and 45, each constructed in the lorm of a U-shaped stamping having laterally spaced side wall portions and a bottom cross web or connecting portion. The toggle link 45 is narrower lor nesting within the outer toggle link 44. Twliis outer toggle link has an extending integral arm portion 46 serving as a contact bridging member for wiping acrossthe surfaces of the contacts 32 and 33.

The toggle links 44 and 45 are pivoted upon the pin 43, which passes through aligned circular holes in the side wall portions of the two toggle links. The toggle links arealso provided with suitable slots formed in their end web surfaces which are adapted to receive the inturned ends 41 of a-spring member 48 which is biased at its lower end on the top surface of the spring member 39 and is provided with an extending tongue portion 49 having engagement in the groove 40 formed in the upstanding tongue 38of the mechanism.

This U-shaped or bowed spring 48 exerts inwardly acting spring pressure on the two toggle members 44 and 45 along a line of action which ,is substantially defined as a straight line extending between the inturned ends 41, 41 of this spring. When this line of action is below the axis of the knuckle pivot 43, the spring pressure revolves the two toggle members into the posi- A tions shown in Figure 2, and when this line of action is above the axis of the knuckle pin the spring pressure revolves the toggle members into the position shown in Figure 3A.

In the operation of the switch shown in Figures 1 to 3A, depression of the plunger I3 by engagement of the cap I4 by the drivers foot results in downward movement of the links 2 0 carried by the pin 22 at the lower end of the plunger. The ends 50' of the links, which are offset axially-therefrom, engage the top of the pin 43, as shown in Figure 2, and move this pin downwardly within the slots 42. The spring I9 serves to maintain the links 20 in overlapping position. Downward movement of the pin in the slots 42 passes the pin downwardly below the line of action of the spring member 48, i. e. over the center of the toggle connection provided between the ends 41 bf the spring member 48 and the center line of the pin, thereby snapping the links 44 and 45 into opposite toggle position, with their upper web edges in close proximity, at the same time moving the contact bridging member 46 from the contact surface 33 to the contact 32, and thus shifting the headlight circuit from either bright to dim circuit position, or vice versa. The plunger then moves upwardly under pressure of spring 23.

Since the pin 43 has moved to the bottoms of the slots 42' as it snaps past over center position, the upper web portions of toggle links 44 and 45 are disposed in such relation to the links 20 that they move beneath the surfaces 52 toward the oiset ends of the links 20, thus providing a clearance for these web portions to snap toward each other. The switch has now assumed the position Shown in detail in Figure 3A.

When it is desired to again shift the circuit, the plunger I3 is again depressed by the foot. This moves the surfaces 52 of' links 20 down into engagement with the upper web portions of toggle links 44 and 45. Further downward movement of the plunger` rotates links 44 and 45 in opposite directions about pin 43, spreading the upper web portions apart against the pressure of spring 48. The frictional pressure engagement between surfaces 52 of links 20 and these upper web portions spreads the lower ends of the links apart against the relatively weak pressure of spring I 9. This is clearly shown in Figure 3. As the toggle links rotate further, the line of action of the spring ends 41 move below the center of pin 43, snapping the pin over center and consequently snapping the links 44 and 45 to the position 4shown in Figure 2, relieving the engagement besurface of pin 43, as shown in Figure 2', thereby repeating the cycle of movement from the position shown in Figure 2 to that shown in Figure 3A.

It is to be noted that the links 20 are provided with offset portions extending inwardly below the lower end of the insulating barrier member I6, whereby the extending edges of the links 20 lie in substantially the. same plane, and engage the upper surface of the pin member 43, in the position shown in Figure 2, in such manner that the Vlinks 20 are not spread outwardly, but remain in their normal position to push the pin member 43 downwardly against the pressure of spring 48 to snap the switch toggle links into the other switching position. The spring I9 returns the links to overlapping position after completion of the movement'described in Figure 3.

Referring nowin detail to the modified switch construction shown in Figures 4 to 10, inclusive, I have provided a switch supporting plate or bracket 55, having extruded openings 56 for receiving suitable securing means for fastening the bracket to a supporting surface, and also having a switch housing-51 provided with outwardly extending flangel portions 5S adapted to be secured to the bracket 55 by rivets or in any other suitable or desired manner. The switch housing 51 is formed in substantially the same manner as described in connection with the switch housing 1 of Figure Land has the integrally formed tab members59 adapted to be bent over a switch terminal plate 60 carrying the contacts 62 for connection to the various circuits.

Mounted substantially centrally of the switch housing 51 on the opposite side of the bracket 55 is the cylindrical sleeve member 63 adapted to form a suitable guide for a switch plunger member including a plunger cap 64 having secured thereto a U-shaped bracket member 65 provided with outwardly extending ears 66 adapted to be riveted to the inner surface of the base of the cap member. The U-shaped bracket 65 is adapted to contain a helically coiled spring 66 which at its lower end is biased again av second U-shaped bracket member 61 extending normal to the bracket member 65 and'forming a boxlike housing for the lower end of the spring member 66. The bracket 61 is slidable with respect tc the bracket 65, and is held against further movement under the influence of spring 66 by the cam surface at the upper end of plunger 68.' The plunger 68 at its lower end is provided with extending arm portions 69 and 10 and an intermediate projecting tongue portion 12. l,The plunger 68 is pivoted about a pin member 13 carried between the arms of the U-shaped bracket 65, the ends of the armsbeing provided with oppositely extending shoulder portions 14 engaging the under surfaceof a supporting plate 15 for preventing outward movement of the plunger assembly under the inuence of the helically coiled spring 16 bearing against the cap member 64 and bearing at its opposite end against` the surface of the plate or bracket 55 within the cylinder 63. The plunger 68 has a 'opposed openings for providing a bearing for the plate 18 about the shaft 11. The plate 18 is also provided with integrally formed extending stop members adapted to have engagement with the upper ends of a U-shaped stop bracket 82' secured in the base oi the switch housing whereby rotation or rocking movement of the plate 18 about the shaft 11 is limited by the ends of the stop member 82 engaging the stop members 80 formed integrally with the plate 18.

The plate 18 is also provided with actuating lugs 82 extending normal to the plane of the plate, and adapted to be engaged within the respective grooves formed between the shoulders 69 and 10 of the plunger member G8 and the intermediate tongue 12 of the plunger member, as shown in Figure 5, whereby depression of the plunger member upon depression of the capv G4 results in engagement of one of the actuating lugs 82 with the groove between the intermediate member 12 and the outer shoulder 10 of. the plunger member, and downward movement of the plunger results in rocking of the plate 18 about the shaft 11 in a clockwise direction, the plunger 68 pivoting about the pin 13 to accommodate this movement, and being normally biased to its axial position with respect to the bracket 65 by means of the spring member 66 and bracket 61 bearing against the upper end of the plunger 88.

Also mounted upon the shaft 11, and extending between the channel-shaped portion of the plate 18, is a carrier member 84, shown in detail in Figure '1, which member is provided with an opening 85 for receiving the shaft, and with two angularly extending ed'ges 86 and 81 adapted to bear against the side walls of the switch housing 51 as the carrier member is reciprocated from one switch operating position to the other.

The carrier member 84 is provided with a normallyA extending integrallug portion 88 which is adapted to form a suitable support for an in sulating bridge member 89 which is resiliently supported upon the plate 84 by means of a leaf spring member S8 of the form generally shown in Figure 6. The insulating member 89 is preferably of sufficient thickness so that the integral tongue 88 of the plate or carrier member 84 does not prei-ect to the opposite surface ofv the mem- "Ul' 89.

The insulating support member 89 is provided with three recessed notches 82, which notches are adapted to be engaged Lf; siiitably extending integr-ai lugs 53 carried by the contact bridging member S4, whereby the bridging member is supported on the insulating support 89 out of electrical connection with the carrier plate 84 or the actuating plate 18.

It will be noted that the web portion of the channel 19 of the plate 18 is provided with a re.- cess or notch 95, which is adapted to be engaged by the integrally extending lug 96 at the end of the spring member 91 shown in Figure 9. Similarly, the carrier plate 84 is provided with a notch 98 adapted to be engaged within the recess 89 formed in the opposite end of the spring member 91.

Similarly to the previously described embodiment, this U-shaped or bowed spring member 91 exerts inwardly acting spring pressure on the two members 18 and 84, this spring pressure being exerted along a line of action which is substantiallyl dened as a straight line extending between the inturned end portions 96 and 99 of said spring. When this line of. action is moved below the axis of the knuckle pivot 11 the spring pressure revolves the two members 18 and 84 into the positions shown -in Figure 5, and when this line of action is moved above the axis of said .knuckle pin the spring pressure revolves said two members in the opposite directions. Y

It will thus be apparent that the plates 18 and 84 form a pair of toggle links mounted about an intermediate fulcrum 11, the ends of the spring member 91 serving to hold the links either in the position shown in Figure 5, in which they are in a toggle position with the axis of the knuckle pivot above the line of action of the ends oi the spring member 91, the spring 91 in this position of the switch being adjacent the lower end of the housing, or, when the plunger is depressed from the position shown in Figure 5 to rock the plate 18 about the shaft 11 in a clockwise direction, the line of action of the ends of the spring member 91 is moved upwardly past the shaft 11 to snap the plate 18 in a clockwise direction toward the right, and to snap the plate 84 in a-counterclock wise direction toward the left, whereby the bridg ing member 94 caried by the plate 84 will be moved from one set of contacts to a second set of contacts for shifting the headlight circuit or the like. As shown in Figure 6, the end of the plunger 68 is rocking the plate 18 past the center position, and the line of action of the ends of the spring 91 is now moving upwardly past the shaft 11, and will snap the plate 18 over to the right against the stop member 82, and will snap the carrier plate 84 to the left so that the wall 86 thereof engages the'side wall of the switch housing 51. The insulating member 89 and the contact bridging member 94 will Vbe carried by the plate 84 to the second position by reason of this snap action.

It is thus apparent that each of the switch constructions disclosed provides for toggle switch link members having a spring member for actuating the same when the line of action of the ends of the spring is moved past the center or common connection of the toggle links, whereby the links are snapped from one switch actuating position to another, and are positively held in each of the switch operated positions by the stress of the spring and the fact that the spring pressure is tending to urge the toggle links further against suitable stop members. Further, it will be noted that the actuation in each case is secured by depression of a reciprocatory plunger, the plunger being provided with an engaging end adapted to provide for reciprceatory or oscillating snap movement of the toggle links from one switch operating position to another.

The switch disclosed in the present invention is of relatively simple design, and has relatively few parts, which can readily be formed from metal stampings or the like, and may be easily assembled into position for operation without the use of tools or the like.

Having described my invention in accordance with the patent statutes, what I claim as new and desire to secure by Letters Patent is:

i mounted on a knuckle pivot, spring means transmitting spring pressure to said toggle member along a line of action extending transversely to the axis of said knuckle pivot whereby to cause rotation of said toggle member about said pivot, and two relatively movable shifter devices carried by said plunger and operative upon one downstroke of the plunger to relatively position the parts of the toggle mechanism with the axis of said knuckle pivot to one side ofv the line of Vaction of said spring means, and operative upon the next downstroke of the plunger to relatively position the parts with the axis of said knuckle pivot to the other side of the line of action of said y spring means.

2. In a foot actuated dimmer switch for motor vehicles, the combination of a plunger, resilient means normally holding said plunger in raised position, switch apparatus comprising movable contact means adapted upon one downstroke of said plunger to be moved into position to control one circuit and adapted upon the next downstroke of said plunger to be moved into position to control another circuit, and toggle mechanism actuated by said plunger for effecting movement of said movable contact means, said toggle mechanism comprising a toggle member pivotally mounted on a knuckle device, a spring device transmitting spring pressure to said toggle member along a line of action extending transversely to the axis of said knuckle device whereby to cause rotation of said toggle member, said knuckle device and said spring device being. arranged whereby both of said devices are capable of being shifted to dispose the axis of said knuckle device to either side of the line of action of said spring device, and means actuated by said plunger for eiecting such shifting movement in one direction on one downstroke of the plunger and effecting such shifting movement in the other l direction on the next downstroke of the plunger.

3. In combination, a plunger, switch apparatus comprising movable contact means adapted upon one stroke of said plunger to be moved into position to control one circuit and adapted upon another stroke of said plunger to be moved into position to control another circuit, and toggle mechanism responsive to said plunger for effecting movement of said movable contact means, said toggle mechanism comprising a knuckle pivot arranged for shifting movement in a path substantially parallel to the path of movement of said plunger, a pair of toggle members pivotally mounted on said knuckle pivot, a bowed spring having inturned ends engaging said toggle members and transmitting inwardly acting spring pressure thereto along a line of action extending transversely to the axis of said knuckle pivot whereby to cause relative rotation between said toggle members, and means pivotally mounted on said plunger and actuated by one stroke oi the plunger to impart shifting movement to said knuckle pivot for shifting the latter to one side of the line of action of said bowed spring, and actuated by the next stroke of the plunger to impart oscillating movement to saidl toggle member for shifting the line of action of said bowed spring to the other side of the axis of said knuckle pivot.

4. In combination, a plunger, switch apparatus comprising movable contact means adapted upon one stroke of said plunger to be moved into position to control one circuit and adapted upon another stroke of said plunger to be moved into position to control another circuit, and toggle mechanism actuated by said plunger for effecting movement of said movable contact, said toggle mechanism comprising a knuckle pivot arranged for shifting movement, two toggle members pivotallyl mounted on said knuckle pivot, spring means transmitting spring pressure to said toggle members along a line of action extending transversely to said knuckle pivot, and means actuated by one stroke of said plunger to shift the axis of said knuckle pivot to one side of the line of action of said spring means, and actuated by another strokeof said plunger to shift the line of action of said spring means back substantially to its original position on the opposite side of the knuckle pivot axis.

5. In combination, a plunger, switch apparatus comprising movable contact means adapted upon one stroke of said plunger to be moved into position to control one circuit and adapted upon another stroke of said plunger to be moved into position to control another circuit, and toggle mechanism actuated by said plunger for effecting movement of ,said movable contact, said toggle mechanism comprising a knuckle pivot arranged for-shifting movement, two toggle members pivotally mounted on said knuckle pivot, spring means transmitting spring pressure to said toggle members along a line of action extending transversely to said knuckle pivot, and shifter mechanism comprising a pair of shifter members pivotally mounted on said plunger, said shifter mechanism being operative during one stroke of said plunger to shift said knuckle pivot across the line of action of said spring means, said shifter members being operative during another stroke of said plunger to oscillate said toggle members for shifting the line of action of said spring means back substantially to its original position on the opposite side of the knuckle pivot axis.

MARION W. MORRIS. 

